Unsaturated carboxylic ester compound, process for producing the same, and composition curable with actinic energy ray

ABSTRACT

An unsaturated monocarboxylic ester compound has at least two structures represented by the following general formula (1): 
                         
wherein R 1  represents a hydrogen atom or an alkyl group of 1 to 6 carbon atoms, and R 2 , R 3  and R 4  independently represent a hydrogen atom, an alkyl group of 1 to 6 carbon atoms, an aryl group, an aralkyl group, a cyano group, a fluorine atom, or a furyl group. A curable composition comprises (A) the unsaturated carboxylic ester compound having two or more structures represented by the general formula (1) mentioned above, (B) a polymerization initiator, and optionally (C) a diluent.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation of Application PCT/JP01/00447, filed Jan. 24,2001, now abandoned.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a new unsaturated carboxylic ester compound,particularly a polyfunctional unsaturated carboxylic ester compound, anda process for the production thereof. Since this unsaturated carboxylicester compound has a photopolymerizable double bond, it can beadvantageously used as a photocurable component and a reactive diluent,for example, of an actinic energy ray-curable composition which hardensby irradiation of an actinic energy ray.

The present invention further relates to a curable compositioncontaining the above-mentioned unsaturated carboxylic ester compound,which composition hardens promptly by irradiation of an actinic energyray such as an ultraviolet ray or an electron beam or further hardens byheating, thereby giving rise to a cured product excelling inadhesiveness to a substrate, particularly a composition curable with anactinic energy ray. This composition can be used in various applicationfields as adhesives, coating materials, and resist materials for printedcircuit boards.

2. Description of the Prior Art

The curing of resin by irradiation of an actinic energy ray is widelyutilized in painting of metal, coating of wood, printing ink, electronicmaterials, etc owing to its high curing speed and solvent-free. One ofthe materials mainly used in these fields is an epoxy acrylate. Sincethis compound is obtained by the reaction of an epoxy resin having anoxirane group which is a cyclic ether of three-membered ring and(meth)acrylic acid and contains a polymerizable unsaturated group, it isused in a photocurable composition by mixing with a compound whichgenerates radicals by irradiation of an actinic energy ray(phtopolymerization initiator), and heretofore various studies thereofhave been done. However, the composition containing this compound hadthe problem of being inferior in the adhesiveness to various substratesbecause the composition causes large shrinkage after photocuring andmost of the hydroxyl groups caused by the modification reaction of anepoxy resin are secondary hydroxyl groups. For the purpose of solvingsuch problems, the composition which employs the cationic polymerizationof oxetane as a curing reaction has been proposed. However, the kinds ofmaterials which can be used in this reaction are small in compared witha radically polymerizable monomer, it was possible to attain the desiredproperties of the cured product only with difficulty.

On the other hand, the organic reaction involving the addition reactionof an oxetane ring which is an ether of four-membered ring has beenreported recently. For example, the addition reaction of an oxetanecompound and an active ester (T. Nishikubo and K. Sato, Chem. Lett., 697(1992)) and the synthesis of polyester having a primary hydroxyl groupattached to a side chain thereof by the polyaddition reaction of abisoxetane and a dicarboxylic acid (T. Nishikubo, A. Kameyama, and A.Suzuki, Reactive & Functional Polymers, 37, 19 (1998)) have beenreported.

Furthermore, JP 10-168120,A discloses a method of producing a resin ofthe actinic energy ray-curing type by carrying out ring opening additionof an oxetane group-containing (meth)acrylate monomer to a carboxylgroup-containing resin or by effecting ring opening addition of acarboxyl group-containing unsaturated monomer to an oxetanering-containing resin. However, these articles make no mention of thecompounds of the present invention and the actinic energy ray-curablecompositions using them.

SUMMARY OF THE INVENTION

An object of the present invention is, therefore, to provide anunsaturated carboxylic ester compound which, when used as a photocurablecomponent, cures promptly by short-time irradiation of an actinic energyray or further by heating, thereby giving rise to a cured productexcelling in adhesiveness to various substrates and many otherproperties, particularly a polyfunctional unsaturated carboxylic estercompound.

Another object of the present invention is to provide a process which iscapable of producing such an unsaturated carboxylic ester compound withsufficient productivity.

A further object of the present invention is to provide a curablecomposition which hardens promptly by short-time irradiation of anactinic energy ray or further hardens by heating and allows a curedproduct excelling in adhesiveness and other properties to be obtained,particularly a composition curable with an actinic energy ray.

To accomplish the objects mentioned above, in accordance with one aspectof the present invention, there is provided an unsaturated carboxylicester compound having at least two structures represented by thefollowing general formula (1):

wherein R¹ represents a hydrogen atom or an alkyl group of 1 to 6 carbonatoms, and R², R³ and R⁴ independently represent a hydrogen atom, analkyl group of 1 to 6 carbon atoms, an aryl group, an aralkyl group, acyano group, a fluorine atom, or a furyl group.

The unsaturated carboxylic ester compound mentioned above is capable ofcuring promptly by irradiation of an actinic energy ray owing to thespecific structure having a photopolymerizable unsaturated double bondand a primary hydroxyl group in combination. Furthermore, it is possibleto thermally cure the compound by heat radicals owing to the presence ofthe unsaturated double bond and also by addition of a curing agent (forexample, isocyanates) which can react with a hydroxyl group owing to thepresence of the primary hydroxyl group at a side chain mentioned above.Particularly, in the case of a polyfunctional unsaturated carboxylicester compound, it cures promptly by short-time irradiation of anactinic energy ray and the resultant cured product exhibits excellentadhesiveness to various substrates owing to the primary hydroxyl group.

In accordance with another aspect of the present invention, there isprovided a process of producing an unsaturated carboxylic ester compoundcharacterized by comprising causing the reaction of (a) a compoundcontaining at least two oxetanyl groups with (b) an unsaturatedcarboxylic acid in the presence of a reaction promotor, therebyproducing a compound having at least two structures represented by thegeneral formula (1) mentioned above. According to such a process, theunsaturated carboxylic ester compound as mentioned above can be producedwith a high yield.

According to yet another aspect of the present invention, there isprovided a curable composition. One embodiment thereof contains (A) anunsaturated carboxylic ester compound having at least two structuresrepresented by the general formula (1) mentioned above and (B) apolymerization initiator as indispensable components thereof. As apolymerization initiator to be used herein, a photopolymerizationinitiator (photo-radical polymerization initiator) and/or a heat-radicalpolymerization initiator may be used.

Another preferred embodiment of the curable composition of the presentinvention contains (A) a polyfunctional unsaturated carboxylic estercompound having at least two structures represented by the generalformula (1) mentioned, (B) a photopolymerization initiator, and (C) adiluent as indispensable components thereof.

In a preferred embodiment, the polyfunctional unsaturated carboxylicester compound (A) mentioned above is a compound obtained by theaddition reaction of (a) a polyfunctional oxetane compound containing atleast two oxetanyl groups and (b) an unsaturated carboxylic acid and, asthe above-mentioned unsaturated carboxylic acid (b), acrylic acid and/ormethacrylic acid prove to be desirable.

The actinic energy ray-curable composition of the present inventioncontaining the aforementioned polyfunctional unsaturated carboxylicester compound as a photocurable component hardens by short-timeirradiation of an actinic energy ray with little shrinkage on curing,and a cured product excelling in adhesiveness to various substrates andin dimensional stability is obtained.

BRIEF DESCRIPTION OF THE DRAWING

The single FIGURE shows the nuclear magnetic resonance spectrum of theunsaturated carboxylic ester compound obtained in Example 1.

DETAILED DESCRIPTION OF THE INVENTION

The present inventors, after pursuing a diligent study to solve theproblems mentioned above, have found that an unsaturated carboxylicester compound of the specific structure having a primary hydroxyl groupproduced by the ring opening reaction of an oxetane ring and aphotopolymerizable unsaturated double bond is capable of curing promptlyby irradiation of an actinic energy ray, that it is possible tothermally cure the compound by heat radicals owing to the presence ofthe unsaturated double bond and also by addition of a curing agent (forexample, isocyanates) which can react with a hydroxyl group owing to thepresence of the primary hydroxyl group at a side chain mentioned above,and further that the compound exhibits excellent adhesiveness to varioussubstrates. The present inventors have further found that an actinicenergy ray-curable composition containing the aforementioned compound asa photocurable component hardens by short-time irradiation of an actinicenergy ray, thereby giving rise to a cured product excelling inadhesiveness to various substrates. Further, they have found anindustrially advantageous process for producing such a compound. As aresult, the present invention has been perfected.

Specifically, the unsaturated carboxylic ester compound having at leastone structure represented by the general formula (1) mentioned above iscapable of curing by irradiation of an actinic energy ray owing to thestructure having a photopolymerizable unsaturated double bond,particularly (meth)acryloyl group. Particularly, in the case of apolyfunctional unsaturated carboxylic ester compound, it cures promptlyby short-time irradiation of an actinic energy ray. Furthermore, it ispossible to thermally cure the compound by heat radicals owing to thepresence of the unsaturated double bond and also by addition of a curingagent (for example, isocyanates) which can react with a hydroxyl groupowing to the presence of the primary hydroxyl group at a side chainmentioned above. The resultant cured product exhibits excellentadhesiveness to various substrates owing to the hydrogen bonding natureof the primary hydroxyl group.

The unsaturated carboxylic ester compound having a primary hydroxylgroup and an unsaturated double bond in combination in its moleculerepresented by the general formula (1) mentioned above can be producedby causing the reaction of (a) a polyfunctional oxetane compoundcontaining two or more oxetanyl groups with (b) an unsaturatedcarboxylic acid in the presence of a reaction promotor, such as atertiary amine, a quaternary onium salt, and a tertiary phosphine.Incidentally, when a polyfunctional unsaturated carboxylic acid havingtwo or more carboxyl groups is subjected to the addition reaction, across-linking reaction will take place, which will result in gelation.For that reason, the unsaturated carboxylic acid is used in the presentinvention. Since the resultant reaction product has a primary hydroxylgroup, it is possible to obtain a cured product which has excellentadhesiveness to a substrate.

This reaction process is illustrated as follows.

The oxetane compound (a) to be used for the above-mentioned reaction isnot limited to a particular one insofar as it has at least two oxetanylgroups in its molecule. In order to introduce two or more unsaturateddouble bonds and primary hydroxyl groups thereinto for the purpose ofincreasing the photocuring properties and adhesiveness, it is desirableto use a polyfunctional oxetane compound containing two or more oxetanylgroups in its molecule. Incidentally, in the case of the polyfunctionaloxetane compound, it is preferred to have a branched from in terms ofthe printing properties or thixotropic properties of a compositioncontaining the resultant product.

As typical examples of the compound containing two oxetane rings in itsmolecule, a bisoxetane represented by the following general formula (2)may be cited.

In the general formula (2) mentioned above, R¹ represents the samemeaning as mentioned above, and R⁵ represents a bivalent group selectedfrom among linear or branched saturated hydrocarbons of 1 to 12 carbonatoms, linear or branched unsaturated hydrocarbons of 1 to 12 carbonatoms, aromatic hydrocarbons represented by the following formulas (A),(B), (C), (D), and (E), linear or cyclic alkylene groups containing acarbonyl group and represented by the following formulas (F) and (G),and aromatic hydrocarbons containing a carbonyl group and represented bythe following formulas (H) and (I).

wherein R⁶ represents a hydrogen atom, an alkyl group of 1 to 12 carbonatoms, an aryl group, or an aralkyl group, R⁷ represents —O—, —S—,—CH₂—, —NH—, —SO₂—, —CH(CH₃)—, —C(CH₃)₂—, or —C(CF₃)₂—, and R⁸represents a hydrogen atom or an alkyl group of 1 to 6 carbon atoms.

Wherein n represents an integer of 1 to 12.

As typical examples of the compound containing three or more oxetanerings in its molecule, etherified products of an oxetane with a hydroxylgroup-containing resin such as a novolak resin, poly(p-hydroxy styrene),calixarene compounds, or a silicone resin like a silsesquioxane besidesa compound represented by the following general formula (3) may becited. In addition thereto, a copolymer of an unsaturated monomercontaining an oxetane ring and an alkyl (meth)acrylate may be cited. Theterm “(meth)acrylate” as used in the present specification referscollectively to acrylate and methacrylate. This

holds good for other similar expression.

In the general formula (3) mentioned above, R¹ represents the samemeaning as mentioned above, and R⁹ represents a residue of the hydroxylgroup-containing resin of the etherified product mentioned above, abranched alkylene group of 1 to 12 carbon atoms represented by thefollowing formula (J), (K) or (L), or an aromatic hydrocarbonrepresented by the following formula (M), (N) or (P), and m representsthe number of functional groups bonded to the residue R⁹, an integer ofthree or more, preferably an integer of 3 to 5,000.

wherein R¹⁰ represents a hydrogen atom, an alkyl group of 1 to 6 carbonatoms, or an aryl group.

As the unsaturated carboxylic acid (b) to be used for the reactionmentioned above, a compound containing a polymerizable unsaturated groupand a carboxylic group in combination in its molecule is preferable. Asconcrete examples, acrylic acid, methacrylic acid, cinnamic acid,crotonic acid, sorbic acid, α-cyanocinnamic acid, β-styryl acrylic acid,etc. may be cited. Alternatively, a half ester of a dibasic acidanhydride with a (meth)acrylate having a hydroxyl group may be used. Asconcrete examples, the half esters of the acid anhydride such asphthalic acid, tetrahydrophthalic acid, hexahydrophthalic acid, maleicacid, and succinic acid with the hydroxyl group-containing(meth)acrylate such as hydroxyethyl acrylate, hydroxyethyl methacrylate,hydroxypropyl acrylate, and hydroxypropyl methacrylate may be cited.These unsaturated carboxylic acids may be used either singly or in theform of a combination of two or more members.

In the reaction mentioned above, the ratio of the oxetanylgroup-containing compound (a) to the unsaturated carboxylic acid (b)(the charging ratio in the reaction mixture) is desired to be in therange of 0.1 to 3.0 mols, preferably 0.3 to 1.5 mols, more preferably0.5 to 1.0 mol, of the unsaturated carboxylic acid per one mol of theoxetanyl group. If the proportion of the unsaturated carboxylic acid islower than 0.1 mol per one mol of the oxetanyl group, the compound willbe at a disadvantage in acquiring insufficient polymerizable groupsintroduced into the product and thus an unduly low photocuringproperties. When the unsaturated carboxylic acid remains in theunreacted state, it may be removed by a well known method such as vacuumdistillation and alkali cleaning.

When the unsaturated carboxylic ester compound of a higher molecularweight is needed, part of the unsaturated carboxylic acid (b) to be usedfor the reaction may be replaced with a polycarboxylic acid orpolyphenol of bifunctionality or more functionality. Particularly, it ispossible to obtain a linear macromolecular compound in the case of thebifunctional carboxylic acid or phenol and a branched macromolecularcompound in the case of the trifunctional carboxylic acid or phenol. Asconcrete examples of the polycarboxylic acid, bifunctional carboxylicacids such as succinic acid, adipic acid, muconic acid, suberic acid,tetrahydrophtalic acid, hexahydrophthalic acid, hexahydroisophthalicacid, phtalic acid, isophtalic acid, and terephtalic acid, andtrifunctional carboxylic acids such as 1,2,3-propane tricarboxylic acid,citric acid, aconitic acid, and trimellitic acid may be cited. Asconcrete examples of the polyphenol, bifunctional phenols such ascatechol, resorcin, hydroquinone, 1,4-naphthalene diol, 1,5-naphthalenediol, bisphenol A, and biphenol, and trifunctional phenols such as2,4,4′-trihydroxybenzophenone and 4,4′,4″-methylidene trisphenol may becited.

As a reaction promotor, any compound may be arbitrarily selected fromamong a tertiary amine, a tertiary amine salt, a quaternary onium salt,a tertiary phosphine, a crown ether complex, and a phosphonium ylide.These compounds may be used either singly or in the form of acombination of two or more members.

As the tertiary amine, triethylamine, tributylamine, DBU(1,8-diazabicyclo[5.4.0]undeca-7-ene), DBN(1,5-diazabicyclo[4.3.0]nona-5-ene), DABCO(1,4-diazabicyclo[2.2.2]octane), pyridine, N,N-dimethyl-4-aminopyridine, etc. may be cited.

As the tertiary amine salt, U-CAT series of Sun-Apro K.K., for example,may be cited.

As the quaternary onium salt, ammonium salts, phosphonium salts,arsonium salts, stibonium salts, oxonium salts, sulfonium salts,selenonium salts, stannonium salts, iodonium salts, etc. may be cited.Particularly preferable salts are ammonium salts and phosphonium salts.As concrete examples of the ammonium salts, tetra-n-butylammonium halidesuch as tetra-n-butylammonium chloride (TBAC), tetra-n-butylammoniumbromide (TBAB), and tetra-n-butylammonium iodide (TBAI), andtetra-n-butylammonium acetate (TBAAc) may be cited. As concrete examplesof the phosphonium salts, tetra-n-butylphosphonium halide such astetra-n-butylphosphonium chloride (TBPC), tetra-n-butylphosphoniumbromide (TBPB), and tetra-n-butylphosphonium iodide (TBBI),tetraphenylphosphonium halide such as tetraphenylphosphonium chloride(TPPC), tetraphenylphosphonium bromide (TPPB), andtetraphenylphosphonium iodide (TPPI), and ethyltriphenylphosphoniumbromide (ETPPB), ethyltriphenylphosphonium acetate (ETPPAc), etc. may becited.

As the tertiary phosphine, any trivalent organic phosphorus compoundscontaining an alkyl group of 1 to 12 carbon atoms or an aryl group maybe used. As the concrete examples thereof, triethylphosphine,tributylphosphine, triphenylphosphine, etc. may be cited.

Further, a quaternary onium salt obtained by the addition reaction ofthe tertiary amine or the tertiary phosphine with a carboxylic acid or ahighly acidic phenol may be used as the reaction promotor. They may bein the form of a quaternary salt before adding to the reaction system.Alternatively, they may be individually added to the reaction system soas to form the quaternary salt in the reaction system. As the concreteexamples thereof, tributylamine acetic acid salt obtained fromtributylamine and acetic acid and triphenylphosphine acetic acid saltformed from triphenylphosphine and acetic acid.

As concrete examples of the crown ether complex, complexes of crownethers such as 12-crown-4,15-crown-5,18-crown-6,dibenzo-18-crown-6,21-crown-7, and 24-crown-8 with alkali metal saltssuch as lithium chloride, lithium bromide, lithium iodide, sodiumchloride, sodium bromide, sodium iodide, potassium chloride, potassiumbromide, and potassium iodide may be cited.

Although any known compounds obtained by the reaction of a phosphoniumsalt and a base may be used as the phosphonium ylide, a highly stablecompound is preferable from the viewpoint of easy handling. As concreteexamples thereof, (formylmethylene)triphenylphosphine,(acetylmethylene)triphenylphosphine,(pivaloylmethylene)triphenylphosphine,(benzoylmethylene)triphenylphosphine,(p-methoxybenzoylmethylene)triphenylphosphine,(p-methylbenzoylmethylene)triphenylphosphine,(p-nitrobenzoylmethylene)triphenylphosphine,(naphthoyl)triphenylphosphine, (methoxycarbonyl)triphenylphosphine,(diacetylmethylene)triphenylphosphine, (acetylcyano)triphenylphosphine,(dicyanomethylene)triphenylphosphine, etc. may be cited.

The amount of the reaction promotor to be used is preferred to be in theapproximate range of 0.1 to 25 mol %, more preferably 0.5 to 20 mol %,most preferably 1 to 15 mol %, based on one mol of the oxetanyl group.If the amount of the reaction promotor to be used is less than 0.1 mol %of the oxetanyl group, the reaction will not proceed at a practicalreaction speed. Conversely, a large amount exceeding 25 mol % is notdesirable from the economical viewpoint because a remarkable reactionpromotion effect will not be obtained even when the reaction promotor ispresent in such a large amount.

The reaction temperature is preferred to be in the approximate range of100 to 200° C., more preferably 120 to 160° C. If the reactiontemperature is lower than 100° C., the reaction will not proceed to asatisfactory extent. Conversely, the reaction temperature exceeding 200°C. is not desirable from the reasons that the reaction products willtend to cause the thermal polymerization due to the reaction of thedouble bonds thereof and that the unsaturated carboxylic acid having alow boiling point will evaporate. Although the reaction time may besuitably selected depending on the reactivity of the raw materials to beused and the reaction temperature, the preferred reaction time is about5 to 72 hours.

Although the aforementioned reaction proceeds either in the presence ofan organic solvent or in the absence of a solvent, the absence of thesolvent is desirable from the viewpoint of the speed of the reaction.Alternatively, the reaction may be performed in the presence of adiluent because the presence of the diluent makes possible to suppressthe increase in viscosity during the reaction. Although the diluent tobe used is not limited to a particular one insofar as it can keep thereaction temperature, the diluents which can dissolve the raw materialtherein prove to be desirable. When the organic solvent is used as thediluent during the synthesis, the solvent may be removed by a well knownmethod such as vacuum distillation. Furthermore, the production can bealso carried out in the presence of a reactive monomer to be describedhereinafter.

As the organic solvent, any known organic solvents may be used insofaras they will not exert a harmful influence on the reaction and can keepthe reaction temperature. As concrete examples thereof, alcohols such asdiethylene glycol monomethyl ether, diethylene glycol monoethyl ether,dipropylene glycol monomethyl ether, and dipropylene glycol monobutylether; glycol ethers such as ethylene glycol monomethyl ether acetate,diethylene glycol monomethyl ether acetate, diethylene glycol monoethylether acetate, propylene glycol monomethyl ether acetate, anddipropylene glycol monomethyl ether acetate; ethers such as diethyleneglycol dimethyl ether and dipropylene glycol dimethyl ether; ketonessuch as methylisobutyl ketone and cyclohexanone; and aromatichydrocarbons such as toluene and xylene may be cited.

By mixing a photo-radical polymerization initiator and/or a heat radicalpolymerization initiator which generate radicals by irradiation of anactinic energy ray or by heating as the polymerization initiator (B)with one or a mixture of two or more of the unsaturated carboxylic estercompounds, particularly the polyfunctional unsaturated carboxylic estercompounds (A) of the present invention obtained as described above, anactinic energy ray-curable composition or a thermosetting compositionmay be obtained. Further, by adding a reactive monomer as the diluent(C) to the composition, it is possible to improve the phtocuringproperties thereof. Incidentally, the amount of the polyfunctionalunsaturated carboxylic ester compounds (A) to be incorporated in thecurable composition of the present invention, particularly the actinicenergy ray-curable composition is not limited to a particular range.

As the photo-radical polymerization initiator to be used as thepolymerization initiator (B), any known compounds which generateradicals by irradiation of an actinic energy ray may be used. Asconcrete examples thereof, benzoin and alkyl ethers thereof such asbenzoin, benzoin methyl ether, and benzoin ethyl ether; acetophenonessuch as acetophenone, 2,2-dimethoxy-2-phenyl acetophenone and4-(1-t-butyldioxy-1-methylethyl) acetophenone; anthraquinones such as2-methylanthraquinone, 2-amylanthraquinone, 2-t-butyl anthraquinone, and1-chloroanthraquinone; thioxanthones such as 2,4-dimethylthioxanthone,2,4-diisopropylthioxanthone, and 2-chlorothioxanthone; ketals such asacetophenone dimethyl ketal and benzyl dimethyl ketal; benzophenonessuch as benzophenone, 4-(1-t-butyldioxy-1-methylethyl) benzophenone, and3,3′,4,4′-tetrakis(t-butyldioxycarbonyl) benzophenone;aminoacetophenones such as2-methylthio-1-[4-(methylthio)phenyl]-2-morpholino-propane-1-one and2-benzyl-2-dimethylamino-1-(4-morpholinophenyl)-butane-1-one;alkylphosphines such as 2,4,6-trimethylbenzoyl phosphine oxide; andacryzines such as 9-phenyl acryzine may be cited.

These well known and widely used photo-radical polymerization initiatorsmay be used either singly or in the form of a combination of two or moremembers. The amount of the photo-radical polymerization initiator to beused is preferred to be in the range of from 0.1 to 30 parts by weight,based on 100 parts by weight of the unsaturated carboxylic estercompound (A) mentioned above. If the amount of the photo-radicalpolymerization initiator to be used is less than the lower limit of therange mentioned above, the composition will not be photocured byirradiation of an actinic energy ray or the irradiation time should beprolonged, and a coating film of satisfactory properties will beobtained only with difficulty. Conversely, even if the photo-radicalpolymerization initiator is added to the composition in a large amountexceeding the upper limit of the range mentioned above, the compositionwill not attain the further improvement in the curing properties andsuch a large amount is not desirable from the economical viewpoint.

In the curable composition of the present invention, for the purpose ofimproving the curing with an actinic energy ray, a curing promotorand/or sensitizer may be used in combination with the photo-radicalpolymerization initiator mentioned above. As the curing promoters whichare usable herein, tertiary amines such as triethylamine,triethanolamine, 2-dimethylaminoethanol, N,N-(dimethylamino)ethylbenzoate, N,N-(dimethylamino)isoamyl benzoate, andpentyl-4-dimethylamino benzoate; and thioethers such as β-thioglycol maybe cited. As the sensitizer, sensitizing dyestuff such as (keto)cumalinand thioxantene; and alkyl borates of such dyestuff as cyanine,rhodamine, safranine, malachite green, and methylene blue may be cited.These curing promotors and/or sensitizers may be used independentlyeither singly or in the form of a combination of two or more members.The amount of the curing promotors and/or sensitizers to be used ispreferred to be in the range of from 0.1 to 30 parts by weight, based on100 parts by weight of the unsaturated carboxylic ester compoundmentioned above.

As the heat radical polymerization initiators which are usable in thepresent invention, organic peroxides such as benzoyl peroxide, acetylperoxide, methyl ethyl ketone peroxide, lauroyl peroxide, dicumylperoxide, di-t-butyl peroxide, t-butyl hydroperoxide, and cumenehydroperoxide; azo type initiators such as 2,2′-azobisisobutyronitrile,2,2′-azobis-2-methylbutyronitrile, 2,2′-azobis-2,4-divaleronitrile,1,1′-azobis(1-acetoxy-1-phenylethane), 1′-azobis-1-cyclohexanecarbonitrile, dimethyl-2,2′-azobisisobutylate, 4,4′-azobis-4-cyanovalicacid, and 2-methyl-2,2′-azobispropanenitrile may be cited. As thepreferred initiator, 1,1′-azobis(1-acetoxy-1-phenylethane) is citedbecause it is the non-cyane and non-halogen type. The heat radicalpolymerization initiator is used in the range of from 0.1 to 10 parts byweight, preferably from 0.5 to 5 parts by weight, based on 100 parts byweight of the unsaturated carboxylic ester compound mentioned above.

When an organic peroxide which exhibits a lower curing rate is used asthe heat radical polymerization initiator, tertiary amines such astributylamine, triethylamine, dimethyl-p-toluidine, dimethylaniline,triethanolamine, and diethanolamine, or metallic soap such as cobaltnaphthenate, cobalt octoate, and manganous naphthenate may be used as apromotor.

Further, when the addition reaction of the oxetane compound and theunsaturated carboxylic acid is carried out in such a proportion that theequivalent weight ratio of the unsaturated carboxylic acid to theoxetanyl group is less than 1.0 mol (i.e., the case that the oxetanering remains in the resultant ester compound), it is possible to makethe actinic energy ray-curable composition of the present invention toform the radical-cationic hybrid curing system by mixing into thecomposition a cationic polymerization initiator which initiates thecationic polymerization by irradiation of an actinic energy ray. Thus,it is possible to obtain a cured product by using the cationicpolymerization in combination. As the cationic polymerization initiator,various known cationic polymerization initiators such as diaryl iodoniumsalts, triaryl sulfonium salts, thiobistriaryl sulfonium salts,selenonium salts, phosphonium salts may be used. These cationicpolymerization initiators may be used either singly or in the form of amixture of two or more members. The amount of the cationicpolymerization initiator to be incorporated in the actinic energyray-curable composition may be in the conventionally used range, ingeneral not less than 0.05 part by weight, preferably not less than 0.1part by weight, most preferably in the range of 0.5 to 10 parts byweight, based on 100 parts by weight of the unsaturated carboxylic estercompound.

The actinic energy ray-curable composition of the present invention mayincorporate a diluent (C) therein at the time of the synthesis or afterthe synthesis. As the diluent (C), a compound having a polymerizablegroup which is capable of taking part in the curing rection can beadvantageously used. Any known reactive diluents such as monofunctionalacrylates and/or polyfunctional acrylates can be used. As concreteexamples thereof, methyl (meth)acrylate, ethyl (meth)acrylate, n-butyl(meth)acrylate, isobutyl (metha)crylate, 2-ethylhexyl (meth)acrylate,isodecyl (meth)acrylate, lauryl (meth)acrylate, tridecyl (meth)acrylate,stearyl (meth)acrylate, methoxypolyethylene glycol (meth)acrylate,cyclohexyl (meth)acrylate, tetrahydrofurfuryl (meth)acrylate, isobornyl(meth)acrylate, benzyl (meth)acrylate, 2-hydroxyethyl (meth)acrylate,2-hydroxypropyl (meth)acrylate, 2-hydroxybutyl (meth)acrylate,dimethylaminoethyl (meth)acrylate, ethylene glycol di(meth)acrylate,diethylene qlycol di(meth)acrylate, 1,4-butanediol di(meth)acrylate,1,6-hexanediol di(meth)acrylate, trimethylol propane tri(meth)acrylate,glycerin di(meth)acrylate, pentaerythritol tri(meth)acrylate,pentaerythritol tetra(meth)acrylate, dipentaerythritolhexa(meth)acrylate, polyester acrylate, reaction products of dibasicacid anhydrides with alcohols having one or more unsaturated groups inits molecule, etc. may be cited. Further, it is possible to add theorganic solvent as mentioned above to the composition as the diluent forthe purpose of adjusting the viscosity of the composition. The diluents(c) can be used either singly or in the form of a mixture of two or moremembers and the amount thereof is not limited to a particular range.

In order to obtain a cured product in the radical-cationic hybrid curingsystem, a monofunctional and/or polyfunctional oxetane compound my beadded to the composition besides the diluent (C) mentioned above. Asconcrete examples thereof, monofunctional oxetanes such as3-methyl-3-hydroxymethyloxetane, 3-ethyl-3-hydroxymethyloxetane,3-methyl-3-hexyloxymethyloxetane, 3-ethyl-3-hexyloxymethyloxetane,3-methyl-3-(2-ethylhexyloxymethyl)oxetane,3-ethyl-3-(2-ethylhexyloxymethyl)oxetane,3-methyl-3-benzyloxymethyloxetane, 3-ethyl-3-benzyloxymethyloxetane,3-methyl-3-phenoxymethyloxetane, and 3-ethyl-3-phenoxymethyloxetane; andpolyfunctional oxetanes such as oligomers or copolymers ofbis[(3-methyl-3-oxetanylmethoxy)methyl]ether,bis[(3-ethyl-3-oxetanylmethoxy)methyl]ether,1,4-bis[(3-methyl-3-oxetanylmethoxy)methyl]benzene,1,4-bis[(3-ethyl-3-oxetanylmethoxy)methyl]benzene,(3-methyl-3-oxetanyl)methyl acrylate, (3-ethyl-3-oxetanyl)methylacrylate, (3-methyl-3-oxetanyl)methyl methacrylate, and(3-ethyl-3-oxetanyl)methyl methacrylate may be cited.

The actinic energy ray-curable composition of the present invention mayincorporate therein a polymer containing at least one epoxy group and/orvinyl ether group in its molecule or further an oxetane ring-containingcompound or polymer in an amount such that the photocuring properties ofthe composition are not impaired. For example, for the purpose ofimproving the properties of a cured product, epoxy resins and suchresins as a polyether resin, a polyester resin, an alkyd resin, aurethane resin and a silicone resin independently having an epoxy groupor a vinyl ether group may be mixed into the composition. As the epoxyresins, a bisphenol A type epoxy resin, a bisphenol F type epoxy resin,a bisphenol S type epoxy resin, a phenol novolak type epoxy resin, acresol novolak type epoxy resin, a glycidyl type epoxy resin, acycloaliphatic type epoxy resin, etc. may be cited. As the oxetanering-containing resins, a bisphenol A type oxetane resin, a biphenyltype oxetane resin, a phenol novolak type oxetane resin, a cresolnovolak type oxetane resin, a copolymer of oxetane (meth)acrylate andalkyl (meth)acrylate, etc. may be cited. Further, for the sake ofpromoting the reaction of these resins, the composition may incorporatetherein a small amount of a known epoxy curing promotor such as aminecompounds, imidazole compounds, carboxylic acids, phenols, quaternaryammonium salts, and methylol group-containing compounds. By the additionof these thermosetting components to the composition, it is alsopossible to thermally cure the composition by heating the resultantcoating film and to improve various properties such as hardness,resistance to chemicals, and heat resistance.

Further, the actinic energy ray-curable composition mentioned above mayincorporate therein a compound containing at least one epoxy groupand/or vinyl ether group in its molecule such as 3,4-epoxycyclohexylvinyl ether, ethylene glycol monoglycidyl monovinyl ether, triethyleneglycol monoglycidyl monovinyl ether, dipropylene glycol monoglycidylmonovinyl ether, cyclohexyl vinyl ether, benzyl vinyl ether,2-ethylhexyl vinyl ether, triethylene glycol divinyl ether, dipropyleneglycol divinyl ether, 1,4-bisdivinyloxymethyl cyclohexane, an adduct ofisophorone diisocyanate with 4-hydroxybutyl vinyl ether in 1:2 molarratio, and an adduct of hydogenated xylylene diisocyanate with4-hydroxybutyl vinyl ether in 1:2 molar ratio.

Moreover, the actinic energy ray-curable composition of the presentinvention may incorporate therein, as occasion demands, a well known andwidely used filler such as barium sulfate, silica, talc, clay, andcalcium carbonate, a well known and widely used coloring pigment such asphthalocyanine blue, phthalocyanine green, titanium oxide, and carbonblack, and other various additives such as an anti-foaming agent, anadhesiveness-imparting agent, a leveling agent, and a thermalpolymerization inhibitor.

As the light sources for the irradiation of the actinic energy ray whichare advantageously used for the purpose of curing the actinic energyray-curable composition mentioned above include a low-pressure mercurylamp, a medium-pressure mercury lamp, a high-pressure mercury lamp, anultra-high-pressure mercury lamp, a xenon lamp, and a metal halide lamp,for example. Laser beams can be utilized as the actinic ray forexposure. Further, electron beams, α-rays, β-rays, γ-rays, X-rays,neutron beams, etc. may be utilized.

Now, the present invention will be described more specifically belowwith reference to working examples and comparative examples, but thepresent invention is not limited to such examples. Wherever the term“parts” is used hereinbelow, it shall refer to “parts by weight” unlessotherwise specified.

Examples of Synthesis of Unsaturated Carboxylic Ester Compounds

EXAMPLE 1

In a 30 ml flask made of glass, 3.62 g (10 millimols) of terephthalatebisoxetane, 3.44 g (40.0 millimols) of methacrylic acid, 0.42 g (1.0millimol) of tetraphenylphosphonium bromide, 0.01 g of methoquinone, and5 ml of xylene were charged and stirred with a magnet stirrer to leftreacting for 24 hours at 130° C. After completion of the reaction, 50 mlof toluene and 40 ml of a 10% sodium carbonate aqueous solution wereadded to the mixture, the organic layer was removed by using aseparatory funnel, and the organic layer was washed with water twice.After anhydrous sodium sulfate was added to the obtained organic layer,it was dried. Then, after the organic solvent was removed bydistillation under vacuum, 5.6 g of thin brown viscous liquid wasobtained. As a result of the HPLC analysis, it has been confirmed thatthe degree of conversion was 93%. By the measurement of IR spectrum ofthe product, the decrease in absorption caused by the oxetanyl group at980 cm⁻¹ was confirmed. Further, in the ¹H-NMR measurement the signalbased on the oxetanyl group at 4.55 ppm disappeared and signalsoriginated from the addition product at 3.5 ppm, 4.2 ppm and 4.4 ppmappeared as new signals. Therefore, the compound obtained was identifiedas the bifunctional methacrylic ester represented by the followingformula (4). The nuclear magnetic resonance spectrum (solvent: CDCl₃,reference substance: TMS (tetramethyl silane)) of the compound obtainedis shown in the FIGURE.

EXAMPLE 2

The synthesis was carried out by following the procedure of Example 1mentioned above, except that 2.84 g (40.0 millimols) of acrylic acid wasused in place of methacrylic acid. As a result of the reaction, 4.7 g ofbrown viscous liquid was obtained and the degree of conversion was 91%.In the measurement of IR spectrum of the product, the decrease inabsorption caused by the oxetanyl group at 980 cm⁻¹ was found.Therefore, it has been confirmed that the addition reaction proceededproperly and the compound aimed at was produced.

EXAMPLE 3

In a 200 ml flask made of glass, 36.2 g (0.1 mol) of terephthalatebisoxetane, 17.2 g (0.2 mol) of methacrylic acid, 2.64 g (5.0 millimols)of tetraphenylphosphonium bromide, and 0.2 g of methoquinone werecharged and stirred for 24 hours at 130° C. without using a solvent. Thereaction product exhibited an acid value of 23.7 mg KOH/g and the rateof addition reaction was 85%. The hydroxyl value of the product was 141mg KOH/g.

EXAMPLE 4

In a 200 ml flask made of glass, 36.2 g (0.1 mol) of terephthalatebisoxetane, 17.2 g (0.2 mol) of methacrylic acid, 2.64 g (5.0 millimols)of tetraphenylphosphonium bromide, and 0.2 g of methoquinone werecharged and stirred for 12 hours at 150° C. At this time, the reactionmixture had an acid value of 0 mg KOH/g. The hydroxyl value of thereaction product was 150 mg KOH/g.

EXAMPLE 5

In a 200 ml flask made of glass, 36.2 g (0.1 mol) of xylylenebisoxetane, 17.2 g (0.2 mol) of methacrylic acid, 2.64 g (0.01 mol) oftriphenylphosphine, and 0.2 g of methoquinone were charged and stirredfor 36 hours at 130° C. At this time, the reaction mixture had an acidvalue of 0 mg KOH/g. The hydroxyl value of the reaction product was 207mg KOH/g.

EXAMPLE 6

In a 200 ml flask made of glass, 36.2 g (0.1 mol) of terephthalatebisoxetane, 17.2 g (0.2 mol) of methacrylic acid, 2.1 g (0.005 mol) oftetraphenylphosphonium bromide, and 0.2 g of methoquinone were chargedand stirred for 15 hours at 130° C. The reaction product exhibited anacid value of 23.7 mg KOH/g. The varnish thus obtained will be referredto hereinafter as “A varnish”.

EXAMPLE 7

In a 200 ml flask made of glass, 36.2 g (0.1 mol) of terephthalatebisoxetane, 17.2 g (0.2 mol) of methacrylic acid, 2.64 g (0.01 mol) oftriphenylphosphine, and 0.2 g of methoquinone were charged and stirredfor 24 hours at 130° C. The reaction product exhibited an acid value of23.7 mg KOH/g. The varnish thus obtained will be referred to hereinafteras “B varnish”.

EXAMPLE 8

In a 200 ml flask made of glass, 36.2 g (0.1 mol) of xylylenebisoxetane, 17.2 g (0.2 mol) of methacrylic acid, 2.1 g (0.005 mol) oftetraphenylphosphonium bromide, and 0.2 g of methoquinone were chargedand stirred for 24 hours at 140° C. The reaction product exhibited anacid value of 13.5 mg KOH/g. The varnish thus obtained will be referredto hereinafter as “C varnish”.

EXAMPLE 9

The synthesis was carried out by following the procedure of Example 6,except that the amount of methacrylic acid was changed to 8.6 g (0.1mol). As a result, a compound having an oxetane ring and an unsaturateddouble bond in combination was obtained. The varnish thus obtained willbe referred to hereinafter as “D varnish”.

Examples of Actinic Energy Ray-Curable Composition

EXAMPLE 10

The following components using the A varnish obtained in Example 6 werekneaded with a three-roll mill to obtain an actinic energy ray-curablecomposition.

A varnish 100 parts Pentaerythritol triacrylate 10 parts Irgacure 184 3parts (photopolymerization initiator manufactured by Ciba SpecialtyChemicals Co.) Silicone type anti-foaming agent 1 part Hydroxyethylmethacrylate 5 parts Total 119 parts

This composition was applied to a copper plate by using a bar coater ina thickness of 25 μm and irradiated with an actinic energy ray by theuse of an ultraviolet light conveyor exposure device (light source:metal halide lamp) till a calculated dose of 3,000 mJ/cm². As a result,the composition was completely cured and a rigid film which does notdissolve in tetrahydrofuran (TFH) was formed.

EXAMPLE 11

The following components using the B varnish obtained in Example 7 werekneaded with a three-roll mill to obtain an actinic energy ray-curablecomposition.

B varnish 100 parts Pentaerythritol triacrylate 10 parts Irgacure 184 3parts Silicone type anti-foaming agent 1 part Hydroxyethyl methacrylate5 parts Total 119 parts

This composition was applied to a copper plate and irradiated with anactinic energy ray in the similar manner as in Example 10. As a result,the composition was completely cured and a rigid film was formed.

EXAMPLE 12

The following components using the C varnish obtained in Example 8 werekneaded with a three-roll mill to obtain an actinic energy ray-curablecomposition.

C varnish 100 parts Pentaerythritol triacrylate 10 parts Irgacure 184 3parts Silicone type anti-foaming agent 1 part Hydroxyethyl methacrylate5 parts Total 119 parts

This composition was applied to a copper plate and irradiated with anactinic energy ray in the similar manner as in Example 10. As a result,the composition was completely cured and a rigid film was formed.

EXAMPLE 13

The following components using the D varnish obtained in Example 9 werekneaded with a three-roll mill to obtain an actinic energy ray-curablecomposition.

D varnish 100 parts Dipentaerythritol hexaacrylate 10 parts Irgacure 1843 parts SP-150 (cationic polymerization initiator 3 parts manufacturedby Asahi Denka Kogyo K.K.) 3-ethyl-3-hydroxymethyl oxetane 10 partsTotal 126 parts

This composition was applied to a copper plate and irradiated with anactinic energy ray in the similar manner as in Example 10. As a result,a tack-free coating film was formed.

COMPARATIVE EXAMPLE 1

The following components were kneaded with a three-roll mill to obtainan actinic energy ray-curable composition.

Epoxy acrylate 100 parts (Acrylated product of EPIKOTE 1001 (product ofYuka-Shell Epoxy K.K.)) Pentaerythritol triacrylate 10 parts Irgacure184 3 parts Silicone type anti-foaming agent 1 part Hydroxyethylmethacrylate 10 parts Total 124 parts

This composition was applied to a copper plate and irradiated with anactinic energy ray in the similar manner as in Example 10. As a result,a tack-free coating film was formed. However, it has been found thatcracks occurred in the coating film due to volume shrinkage on curingand the separation thereof from the base material was observed.

Since the aforementioned unsaturated carboxylic ester compound of thepresent invention has a photopolymerizable unsaturated double bond and aprimary hydroxyl group in combination, it is capable of curing promptlyby irradiation of an actinic energy ray, thermally curing by heatradicals owing to the presence of the unsaturated double bond and alsothermally curing by addition of a curing agent (for example,isocyanates) which can react with a hydroxyl group owing to the presenceof the primary hydroxyl group at a side chain mentioned above.Accordingly, this compound can be used as a curable component in variousapplication fields. Particularly, in the case of a polyfunctionalunsaturated carboxylic ester compound, it cures promptly by short-timeirradiation of an actinic energy ray and the resultant cured productexhibits excellent adhesiveness to various substrates owing to theprimary hydroxyl group. Accordingly, the polyfunctional unsaturatedcarboxylic ester compound of the present invention can be advantageouslyused in various application fields as a photocurable component and areactive diluent, for example, of an actinic energy ray-curablecomposition which hardens by irradiation of an actinic energy ray.

Further, the curable composition of the present invention containingsuch an unsaturated carboxylic ester compound as a curable component,particularly the actinic energy ray-curable composition containing thepolyfunctional unsaturated carboxylic ester compound as a photocurablecomponent makes possible to obtain a cured product excelling indimensional stability with little shrinkage on curing by short-timeirradiation of an actinic energy ray. Accordingly, this composition canbe advantageously used in various application fields as various kinds ofprotective film, coating materials, adhesives, sealing compounds,printing ink, electrical insulating materials, various resists andinterlaminar insulating materials for printed circuit boards, and thelike.

While certain specific working examples have been disclosed herein, theinvention may be embodied in other specific forms without departing fromthe spirit or essential characteristics thereof. The described examplesare therefore to be considered in all respects as illustrative and notrestrictive, the scope of the invention being indicated by the appendedclaims rather than by the foregoing description and all changes whichcome within the meaning and range of equivalency of the claims are,therefore, intended to be embraced therein.

1. An unsaturated carboxylic ester compound derived from the reaction of(a) an oxetane compound containing at least two oxetanyl groups with (b)an unsaturated monocarboxylic acid and having at least two discretestructures represented by the following general formula (1):

wherein R¹ represents a hydrogen atom or an alkyl group of 2 to 6 carbonatoms, R² represents a hydrogen atom or a methyl group, and R³ and R⁴independently represent a hydrogen atom, wherein said oxetane compound(a) is selected from the group consisting of a bisoxetane compoundrepresented by the following general formula (2) and a polyfunctionaloxetane compound represented by the following general formula (3), andsaid unsaturated monocarboxylic acid (b) is selected from the groupconsisting of acrylic acid and methacrylic acid,

wherein, R¹ represents a hydrogen atom or an alkyl group of 2 to 6carbon atoms, and R⁵ represents a bivalent group selected from the groupconsisting of linear or branched saturated hydrocarbons of 2 to 12carbon atoms, linear or branched unsaturated hydrocarbons of 2 to 12carbon atoms, aromatic hydrocarbons represented by the followingformulas (A), (B), (C), (D), and (E):

wherein R⁶ represents a hydrogen atom, an alkyl group of 1 to 12 carbonatoms, an aryl group, or an aralkyl group, R⁷ represents —O—, —S—,—CH₂—, —NH—, —SO₂—, —CH(CH₃)—, —C(CH₃)₂—, or —C(CF₃)₂—, and R⁸represents a hydrogen atom or an alkyl group of 1 to 6 carbon atoms,linear or cyclic alkylene groups containing a carbonyl group andrepresented by the following formulas (F) and (G):

wherein n represents an integer of 1 to 12, and aromatic hydrocarbonscontaining a carbonyl group and represented by the following formulas(H) and (I):

wherein, m represents the number of functional groups bonded to aresidue R⁹ and an integer of not less than three, R¹ represents ahydrogen atom or an alkyl group of 2 to 6 carbon atoms, and R⁹represents a residue of an etherified product with oxetane and eitherone of a novolak resin residue, a poly(p-hydroxy styrene) residue, acalixarene residue, a residue of a silicone resin, a branched alkylenegroup represented by the following 10 formula (J), (K) or (L):

 or an aromatic hydrocarbon represented by the following formula (M),(N) or (P):

wherein R¹⁰ represents a hydrogen atom, an alkyl group of 1 to 6 carbonatoms, or an aryl group.
 2. The unsaturated carboxylic ester compoundaccording to claim 1, wherein the substituent R¹ in said general formula(1) is an ethyl group.